Mike;

If, after removing nut, and using the biggest (3/4" drive if possible), on bolt head with longest extension (car would have to be raised on stands...on a lift would be even better), you can get bolt to turn at all, there is a chance on soaking Liquid Wrench, or PB Blaster, or Croil (any good penetrating oil!) into the rust to free it up...but if bolt cannot be turned with the biggest wrench/highest torque (or air driven impact socket) you can get on it, it will likely have to be sacrificed to remove.

Using torch heat on bolt may help, but will certainly toast the bushings (but bolt is likely being removed for this in the first place).

...and how are you certain it's "visibly bent"...that would mean crossmember is possibly bent too...but if indeed it is, that is not going to make removal any easier...

I agree with Eric...one mans tapping is another man's beating the S**T out of...but whatever you try DO Not Damage threads as these are necessary to employ a Trick 17 pulling removal technique:

Once all options are exhausted (including tapping or btsoo) cut head off bolt and pull it out using Trick 17...see: http://www.sw-em.com/Trick%2017.htm ...then, I'd take Eric up on his offer for a good used one, and install it with lots of anti-seize!

Good hunting!

I live in a big city so I I go to the best fastener supplier in town I can order anything I want, the length would be the challenge as u need smooth shaft for most of it, sometimes I need to tap threads a little closerto my dimension. I also cut to length.
Vis a vis removal,it's of heat....ie red hot if required, maybe do some research on hardening the steel afterwards if u really have to go for it.....
Maybe try online for bolts that are close and same quality.

"If you need to tap it out, put the nut back on partway so you don't damage the threads."

The word 'tap' in that statement is what I take issue with (sorry Phil :) )

Lots of WD40, or penetrant of your choice. Heat to a limited amount (just the sleeve is the goal), and a frickin' sledge hammer. A hammer drill, perhaps, could work. I've never tried it, as I've never had one at the time. But I might try it now.

Good luck! I feel for you. Been there. Have trashed cars for less, and that's frustrating as hell.

Consider yourself VERY lucky that it's only stuck in the bushing sleeve!

--
-Matt I ♥ my ♂

Unless you can get the sleeve to loosen its grip on the bolt, you may not have a choice but to cut the bolt.

I suggest cutting the bolt as close to the crossmember tube as possible. Be careful not to damage the tube.

New bolts from Volvo are now over $90.00.

I should have some good used ones for $15.00 each.

I might be able to get new ones for around $30.00 a piece.
--
Eric
Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
Torrance, CA 90502